K2 Outage

OBJECTIVES

The objectives of the project were to deliver specialised Non-Destructive Testing (UT, MPI,PAUT, RT, VT) and Mechanical services (rigging, welding) with precision and expertise. The project aimed to be completed within the specified timeframe, ensuring timely delivery and adherence to deadlines. Maintaining a positive reputation through effective communication and management was a key focus, fostering a strong relationship with the client. Additionally, the project was designed to address and efficiently manage any emergent work, ensuring all unexpected issues were resolved promptly and effectively.

SCOPE / SERVICES PROVIDED

The services provided were comprehensive and multifaceted, focusing on both Non-Destructive Testing (NDT) and Mechanical services. The NDT services included advanced techniques such as Ultrasonic Testing (UT), Magnetic Particle Inspection (MPI), Phased Array Ultrasonic Testing (PAUT), Radiographic Testing (RT), and Visual Testing (VT). These methods were essential for identifying defects and ensuring the structural integrity of critical components.

Additionally, the project involved mechanical services, particularly rigging and welding, which were crucial for the installation and repair tasks required during the outage. Rope Access techniques were employed to reach and perform maintenance on high and difficult-to-access areas safely and efficiently. This combination of NDT, mechanical services, and rope access ensured that all aspects of the project were handled with precision and expertise, contributing to the overall success and safety of the outage.

CHALLENGES AND SOLUTIONS

Throughout the Cement Australia K2 Outage project, several significant challenges were encountered, each requiring strategic and effective solutions to ensure the project remained on track and met the client’s expectations. These challenges included limited pre-planning time due to consecutive shutdowns, the extensive volume of work to be completed, and emergent tasks that arose unexpectedly. By leveraging our national labor pool, efficiently allocating resources, and mobilising specialised mechanical crews, we were able to overcome these obstacles and successfully deliver the project. Below are the specific challenges faced and the solutions implemented to address them:

• Limited pre-planning time due to back-to-back shutdowns before this outage was overcome by leveraging the labor pool nationally.
• The total volume of work was challenging but was solved by efficient labor allocation.
• Installation of 70+ patch plates on the K2 Stack and dealing with incorrect repair consumables on the Kiln were resolved by mobilising a mechanical crew and providing advanced NDT methods (Radiography and Phase Array Ultrasonic Testing).

OUTCOMES

The client’s satisfaction increased notably due to TRA’s effective handling of the project. Our expertise and efficient solutions built a strong relationship of trust, resulting in the clients increased reliance on TRA for future outages. The improved safety measures and advance NDT methods demonstrated our commitment to high quality service and operational excellence.